Ignition Wire Connector Barrel With Dimples For Spark Plug Terminal
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Solution Overview
Problem
Existing ignition wire connectors for internal combustion engines are costly to produce and prone to dislocation during assembly, with prior designs often failing to maintain a secure and continuous electrical connection due to elongated holes and the use of spring clips that can become dislodged.
Innovation Solution
The connector features a barrel with a closed end and an open end, equipped with inwardly-extending dimples that snap onto the spark plug terminal's taper, providing constant radial pressure at four points of contact, thus maintaining a secure and continuous electrical connection without the need for a spring clip.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a spring clip with dimples is used to retain the connector on the spark plug terminal, then the connector can be assembled, but the spring clip can become dislodged and/or dislocated during assembly
Solution Approach 1:
The patent removes the spring clip component entirely from the connector design. Instead of using a separate spring clip with dimples that snaps into the barrel, the invention integrates the retention function directly into the barrel structure through an hourglass shape with a reduced diameter section that mechanically locks onto the spark plug terminal, eliminating the complexity and reliability issues of spring clip assemblies
Solution Approach 2:
The patent combines the retention function and the structural form into a single integrated barrel design. The hourglass shape of the barrel itself provides both the mechanical locking action and the structural support, merging what were previously separate functions (spring clip for retention, barrel for structure) into one unified component
2Ease of manufacture
If the barrel is pierced for through holes and the spring clip is stamped and heat treated, then the spring clip can be assembled to the barrel, but the production cost increases
Solution Approach 1:
The patent eliminates the spring clip component and its associated manufacturing processes (stamping, heat treating, plating, assembly). The retention function is achieved through the barrel's hourglass shape alone, which can be formed in a single molding or forming operation, dramatically simplifying the manufacturing process and reducing production costs
Solution Approach 2:
The barrel in the patent serves multiple functions simultaneously: it provides structural support, electrical connection, and mechanical retention through its hourglass shape. This multi-functionality eliminates the need for separate components and manufacturing steps, improving both ease of manufacture and productivity
3Ease of operation
If the through holes are made in the barrel wall, then the spring clip can be assembled, but the through holes become elongated as the barrel is cupped or drawn up
Solution Approach 1:
The patent removes the through holes and spring clip assembly entirely. The retention mechanism relies on the hourglass shape of the barrel that fits onto the spark plug terminal's geometry, eliminating the precision requirements for hole positioning and the problems of hole elongation during barrel forming
Solution Approach 2:
The patent changes the retention mechanism from a spring-loaded dimensional system (relying on spring force and hole position) to a geometric interference fit system (relying on the hourglass shape and terminal geometry). This parameter change eliminates sensitivity to manufacturing tolerances and hole positioning variations
4Ease of operation
If a single dimple on one side of the barrel is used to target the smaller diameter of the spark plug terminal, then the connector can be assembled, but extreme flex of the barrel occurs and the connection is not maintained
Solution Approach 1:
The patent employs asymmetric hourglass shaping in the barrel that is specifically designed to match the asymmetric geometry of the spark plug terminal. This asymmetric configuration provides stable mechanical retention without causing extreme flexing, as the shape is optimized to fit the terminal's profile rather than forcing a symmetric design onto an asymmetric component
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This design simplifies manufacturing, reduces production costs, and ensures a reliable electrical connection by maintaining constant pressure between the connector and spark plug terminal, improving current flow efficiency and reducing electrical resistance and radio frequency interference.
Implementation Method 1
A paraxial seam permit the barrel to expand in diameter... the barrel expands slightly at the seam to provide an inward radial pressure
Implementation Method 2
The dimples snap onto the spark plug terminal taper... the distance from the dimples to the closed end is set to target the taper just below the bulge/taper junction
Data Source
AI summary
An ignition wire spark plug connector comprising a jack and a wire attachment. The wire attachment is adapted to electrically attach to a wire. The jack is comprised of a barrel with a closed end. The barrel is generally cylindrical with a central space that receives the spark plug terminal through an open end. Dimples in the barrel extend into the central space. The dimples are located to force at least four points of contact between the jack and the spark plug terminal.